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Patrick Kelley (Flion)
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Date:  7-18-2013
Number of Hours:  4.00
Manual Reference:  45-6 and 45-7
Brief Description:  Hinge copilot door

I finished rough trimming the right door today; there's a bit more to do to smooth it out and leave room for paint but it is flush to the fuselage so it was time to install the hinges. You can see my popsicle stick holders in the first image; I also used duct tape per the instructions when it came time to drill the door. But first, lets put the hinges into the cabin top. In the second image, you can see my 1.5 X 1 X .125 spacers which I used to drill the initial hole. Then I used the ruler to line up the hinges and tightened the screw in the first holes before drilling the second, and so on. Then I put the door on and drilled the outboard holes there, substituing bolts instead of screws for the raw holes. In the third image, you can see I'm swapping out the bolts for screws, countersinking as I go. I also went ahead and drilled the left side for the hinges there even though I am still trimming the door there. I also took a little time to figure out how I wanted to attach nutplates to the door hinges as I intend to cover them to facilitate the seal. And I need to pass them to Phil Cobbin to drill and countersink the steel on his mill. It was fun to see the door hinged and working; it was extremely smooth.
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